U.S. patent application number 17/607186 was filed with the patent office on 2022-07-14 for composite pane with a cutout in the inner pane.
The applicant listed for this patent is SAINT-GOBAIN GLASS FRANCE. Invention is credited to Michael KOLF, Christopher MATHEISEN, Gabor VARGA, Dirk WOHLFEIL.
Application Number | 20220219432 17/607186 |
Document ID | / |
Family ID | 1000006301943 |
Filed Date | 2022-07-14 |
United States Patent
Application |
20220219432 |
Kind Code |
A1 |
MATHEISEN; Christopher ; et
al. |
July 14, 2022 |
COMPOSITE PANE WITH A CUTOUT IN THE INNER PANE
Abstract
A composite pane includes an outer pane and an inner pane which
are joined to one another via a first thermoplastic intermediate
layer arranged directly adjacent the outer pane and a second
thermoplastic intermediate layer arranged directly adjacent the
inner pane, and an inlay element which is arranged in a region of
the composite pane between the first thermoplastic intermediate
layer and the second thermoplastic intermediate layer. The inner
pane has a cutout and the second thermoplastic intermediate layer
has a cutout. The cutout of the second thermoplastic intermediate
layer is, when looked through, arranged completely within the
region in which the inlay element is arranged, and the cutout of
the inner pane is, when looked through, arranged completely within
the cutout of the second thermoplastic intermediate layer.
Inventors: |
MATHEISEN; Christopher;
(HERZOGENRATH, DE) ; WOHLFEIL; Dirk; (RAEREN,
BE) ; VARGA; Gabor; (HERZOGENRATH, DE) ; KOLF;
Michael; (ESCHWEILER, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN GLASS FRANCE |
COURBEVOIE |
|
FR |
|
|
Family ID: |
1000006301943 |
Appl. No.: |
17/607186 |
Filed: |
April 16, 2020 |
PCT Filed: |
April 16, 2020 |
PCT NO: |
PCT/EP2020/060728 |
371 Date: |
October 28, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2307/41 20130101;
B32B 3/30 20130101; B32B 17/10036 20130101; B32B 17/10385 20130101;
B32B 17/10779 20130101; B32B 2307/202 20130101; B32B 2605/006
20130101; B32B 17/10935 20130101; B32B 17/10348 20130101; B32B
2307/402 20130101; B32B 17/10357 20130101 |
International
Class: |
B32B 17/10 20060101
B32B017/10; B32B 3/30 20060101 B32B003/30 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 30, 2019 |
EP |
19171753.7 |
Claims
1. A composite pane, comprising: an outer pane and an inner pane
which are joined to one another via a first thermoplastic
intermediate layer arranged directly adjacent the outer pane and a
second thermoplastic intermediate layer arranged directly adjacent
the inner pane, and an inlay element which is arranged in a region
of the composite pane between the first thermoplastic intermediate
layer and the second thermoplastic intermediate layer, wherein the
inner pane has a cutout and the second thermoplastic intermediate
layer has a cutout, and the cutout of the second thermoplastic
intermediate layer is, when looked through, arranged completely
within the region in which the inlay element is arranged, and the
cutout of the inner pane is, when looked through, arranged
completely within the cutout of the second thermoplastic
intermediate layer.
2. The composite pane according to claim 1, wherein the inlay
element comprises a substrate layer and an opaque layer, and the
opaque layer has a cutout which is, when looked through, arranged
completely within the cutout of the inner pane.
3. The composite pane according to claim 1, wherein the inlay
element comprises a substrate layer which is opaquely colored in
some regions and has a region which is excluded from the opaque
coloring and is, when looked through, arranged completely within
the cutout of the inner pane.
4. The composite pane according to claim 2, wherein the substrate
layer contains or consists of an electrically conductive
polymer.
5. The composite pane according to claim 2, wherein the inlay
element has at least one electrically conductive element.
6. The composite pane according to claim 5, wherein, independently
of one another, the at least one electrically conductive element is
implemented as an electrically heatable element, a moisture sensor,
a pressure sensor, an antenna, or a carrier for electronic lines
and components.
7. The composite pane according to claim 5, wherein the at least
one electrically conductive element is an electrically conductive
coating a carbon-containing layer, or a metallic layer or contains
or consists of an electrically conductive polymer.
8. The composite pane according to claim 5, wherein the inlay
element has at least two electrically conductive elements that are
structured differently.
9. The composite pane according to claim 2, wherein the cutout in
the opaque layer is a sensor window for an optical sensor.
10. The composite pane according to claim 2, wherein the substrate
layer contains or consists of polyethylene terephthalate (PET),
polymethyl methacrylate (PMMA), polypropylene (PP), or polyethylene
(PE).
11. The composite pane according to claim 2, wherein the opaque
layer contains or consists of polyethylene terephthalate (PET) or
polyethylene (PE), ethylene vinyl acetate copolymer (EVA).
12. The composite pane according to claim 2, wherein, when looked
through, at least in the region of the cutout, an electrically
conductive element implemented as an electrically heatable element
is arranged.
13. The composite pane according to claim 1, wherein the composite
pane is a windshield that has an upper edge and a lower edge and is
substantially mirror-symmetrical along a center line, and the inlay
element is arranged on the centerline near the upper edge of the
windshield.
14. A method for producing a composite pane according to claim 1,
comprising: (a) providing an outer pane, an inner pane which has a
cutout, a first thermoplastic intermediate layer, a second
thermoplastic intermediate layer which has a cutout, and an inlay
element; (b) arranging the first thermoplastic intermediate layer
directly adjacent the outer pane, the second thermoplastic
intermediate layer directly adjacent the inner pane, and the inlay
element between the first thermoplastic intermediate layer and the
second intermediate layer such that the cutout of the second
thermoplastic intermediate layer is, when looked through, arranged
completely within the region, in which the inlay element is
arranged, and, when looked through, the cutout of the inner pane is
arranged completely within the cutout of the second thermoplastic
intermediate layer; and (c) joining the outer pane to the inner
pane by lamination via the first thermoplastic intermediate layer
and the second thermoplastic intermediate layer.
15. A method comprising utilizing a composite pane according to
claim 1 as a vehicle pane.
16. The composite pane according to claim 10, wherein the substrate
layer contains or consists of polyethylene terephthalate (PET).
17. The composite pane according to claim 11, wherein the opaque
layer contains or consists of polyethylene terephthalate (PET).
18. The method according to claim 15, wherein the composite pane is
a windshield of a motor vehicle.
19. The composite pane according to claim 3, wherein the region of
the substrate layer excluded from the opaque coloring is a sensor
window for an optical sensor.
20. The composite pane according to claim 3, wherein, when looked
through, at least in the region of the substrate layer excluded
from the opaque coloring, an electrically conductive element
implemented as an electrically heatable element is arranged.
Description
[0001] The invention relates to a composite pane with a cutout in
the inner pane, a method for its production, and its use.
[0002] Modern vehicles are equipped with an increasing number of
sensors whose signals are used, for example, to assist the driver.
Examples of such sensors include optical sensors, such as cameras,
for example, video cameras or night vision cameras, rain sensors,
light sensors, or distance meters. Forward-directed sensors are
frequently secured on the interior-side surface of the windshield,
typically centrally near the upper edge. In the prior art, the
sensors are obscured by an opaque masking print on the windshield,
For this, the customary, peripheral, frame-like masking print,
which primarily serves as UV protection for the assembly adhesive
of the windshield, is significantly enlarged in the direction of
the center of the pane in the region of the sensors.
[0003] Conventional sensors are mounted on the windshield such that
their detection direction runs horizontally. Since the windshield
is installed in the vehicle greatly inclined, for example, at an
installation angle of 60.degree. relative to the vertical, the
detection direction of the sensor encloses a very acute angle of
approx. 30.degree. with the windshield, This yields a relatively
large, substantially trapezoidal, so-called "sensor window" of the
windshield. The sensor window is that region of the windshield
through which radiation passing through is detected by the sensor.
The sensor windowof the windshield is, thus, the region that lies
in the detection bean path of the sensor.
[0004] The more sensors to be secured on the pane, the more area of
the windshield is occupied by the total of the sensor windows, and
the larger the masking print intended to obscure the sensors has to
be.
[0005] During the production of a composite pane, the masking print
is applied on the outer pane or the inner pane by screen printing
before the bending of the individual panes. During the bending
process, which is usually carried out at temperatures from
500.degree. C. to 700.degree. C., the heat is absorbed more by the
screen print than by the respective pane. This can result in
optical distortions of sensor windows surrounded by screen
printing, in particular black printing, and/or in glass
breakage.
[0006] The sensorwindows should be kept free of ice or fog. This
can be made possible, for example, by heatable sensor windows. For
this purpose, heating wires are, for example, laminated into the
region of the sensor windows. Such laminated-in heating wires are,
however, disadvantageous for the optical quality of the sensor
windows.
[0007] Nowadays, sensors, heating elements, and antennas are
applied to the inside of the inner pane or incorporated in the
laminate; and the masking print to conceal the sensors, heating
elements, and antennas is applied in a separate step and as a
separate layer. In addition, the individual functional elements,
i.e., the sensors, heating elements, or antennas are applied or
incorporated individually.
[0008] To improve the optical properties of the sensor window, the
inner pane can have a cutout in the region of the sensor window.
Composite panes with a cutout in the inner pane are disclosed, for
example, in WO 2018/142078 A1, WO 2018/178883 A1, WO 2016/208370
A1, and DE 10 2007 042 028 A1. However, such a cutout in the inner
pane of a composite pane consisting of an outer pane, an inner
pane, and at least one thermoplastic intermediate layer is
accompanied by losses in terms of the stability of the composite
pane.
[0009] DE 20 2019 102 137 U1 discloses composite panes with a
cutout in the thermoplastic intermediate layer.
[0010] The object of the present invention is to provide an
improved composite pane in which the risk of glass breakage during
the bending process is reduced, in which the optical quality in the
region of an existing sensor window is improved, which is
stabilized mechanically, and in which, optionally, one or more
electrically conductive elements are incorporated.
[0011] The object of the present invention is accomplished
according to the invention by a composite pane in accordance with
claim 1. Preferred embodiments are apparent from the subclaims.
[0012] The composite pane according to the invention comprises at
least an outer pane and an inner pane, a first thermoplastic
intermediate layer, a second thermoplastic intermediate layer, end
an inlay element, wherein the first thermoplastic intermediate
layer is arranged directly adjacent the outer pane, the second
thermoplastic intermediate layer is arranged directly adjacent the
inner pane, and the inlay element is arranged between the first
thermoplastic intermediate layer and the second thermoplastic
intermediate layer.
[0013] The inlay element is arranged only in one region of the
composite pane, i.e., in terms of its outer dimensions, it is
smaller than the composite pane and thus does not extend over the
entire composite pane. Preferably, the inlay element extends over a
maximum of 50%, particularly preferably over a maximum of 30%, most
particularly over a maximum of 10% of the area of the composite
pane.
[0014] According to the invention, the inner pane has a cutout and
the second thermoplastic intermediate layer also has a cutout.
According to the invention, when looked through, the cutout in the
second thermoplastic intermediate layer is arranged completely
within the region in which the inlay element is arranged. According
to the invention, when looked through, the cutout in the inner pane
is arranged completely within the cutout in the second
thermoplastic intermediate layer.
[0015] The outer pane, the inner pane, the first thermoplastic
intermediate layer, and the second thermoplastic intermediate layer
have substantially the same outer dimensions, They thus extend
substantially over the entire length and width of the composite
pane according to the invention, wherein the second thermoplastic
intermediate layer and the inner pane have a cutout in each case,
as described above, and the first thermoplastic intermediate layer
and the outer pane have no cutout.
[0016] The outer pane and the inner pane are typically made of
glass. The composite pane is, in particular, a vehicle composite
pane and is thus intended for separating a vehicle interior from an
external environment. The composite pane is thus a window pane that
is inserted in a window opening of the vehicle body or is intended
for this. The composite pane according to the invention is in
particular a windshield of a motor vehicle.
[0017] The term "inner pane" refers to that pane that is intended
to face the interior of the vehicle in the installed position.
"Outer pane" refers to that pane that is intended to face the
external environment of the vehicle in the installed position. That
surface of the respective pane that faces the external environment
of the vehicle in the installed position is referred to as the
exterior-side surface. That surface of the respective pane that
faces the interior of the vehicle in the installed position is
referred to as the interior-side surface.
[0018] The region of the composite pane that is arranged in the
detection beam path of a sensor or is intended for that purpose is
referred to as the sensor region or sensor window. Radiation that
passes through the composite pane in the sensor window is detected
by the sensor.
[0019] Preferably, the cutout in the inner pane is suitable as a
sensor window for an optical sensor.
[0020] When the sensor is a camera, the region of the composite
pane that is arranged in the detection beam path or is intended for
that purpose can also be referred to as the camera region or the
camera window. Radiation that passes through the composite pane in
the camera window is detected by the camera.
[0021] In one embodiment of the composite pane according to the
invention, the inlay element comprises a substrate layer and an
opaque layer, wherein the opaque layer has a cutout which, when
looked through, is arranged completely within the cutout in the
inner pane. The substrate layer is preferably transparent.
Preferably, the cutout in the substrate layer is a sensor window
for an optical sensor. Optionally, in this embodiment of a
composite pane according to the invention, when looked through, an
electrically conductive element implemented as an electrically
heatable element is arranged at least in the region of the cutout
in the opaque layer. The optional electrically conductive element
implemented as an electrically heatable element can also be
implemented as an electrically conductive layer or coating that is
applied over the entire surface of the substrate layer.
[0022] Preferably, the opaque layer is arranged directly adjacent
the first thermoplastic layer.
[0023] In another embodiment of the composite pane according to the
invention, the inlay element comprises a substrate layer that is
opaquely colored in some regions and has a region that is excluded
from the opaque coloring, i.e., Is not opaquely colored and is thus
transparent. The region excluded from the opaque coloring is, when
looked through, arranged completely within the cutout in the inner
pane. Preferably, the region of the substrate layer excluded from
the opaque coloring is a sensor window for an optical sensor.
Optionally, in this embodiment of a composite pane according to the
invention, when looked through, an electrically conductive element
implemented as an electrically heatable element is arranged at
least in the region that is excluded from the opaque coloring. The
optional electrically conductive element implemented as an
electrically heatable element can also be implemented as an
electrically conductive layer or coating that is applied to the
entire surface of the substrate layer.
[0024] In preferred embodiments of the composite pane according to
the invention, as described above, the cutout in the opaque layer
or the region of the substrate layer excluded from the opaque
coloring is a sensor window for an optical sensor.
[0025] The area of the cutout in the opaque layer or the area of
the region of a substrate layer colored in some regions excluded
from the opaque coloring preferably corresponds at least to the
size of the sensor window required for the respective sensors,
particularly preferably exactly to the size of the sensor window
required for the respective sensors. The cutout in the opaque layer
or the area of the region of a substrate layer colored in some
regions preferably has an area of at least 1 cm.sup.2, particularly
preferably of 1 cm.sup.2 to 500 cm.sup.2, most particularly
preferably of 10 cm.sup.2 to 250 cm.sup.2, in particular of 20
cm.sup.2 to 100 cm.sup.2, for example, 35 cm.sup.2, The
sensorwindow is, for example, between 7 cm and 10 cm high and
between 8 cm and 40 cm wide.
[0026] In one embodiment, the cutout in the opaque layer or the
region of a substrate layer colored in some regions excluded from
the opaque coloring is trapezoidal. A trapezoidal cutout or a
trapezoidal region excluded from the opaque coloring is, in
particular, suitable as a sensor window for a camera. In another
embodiment, the cutout in the opaque layer or the region of a
substrate layer colored in some regions excluded from the opaque
coloring is circular or oval. A circular or oval cutout or a region
excluded from the opaque coloring is, in particular, suitable as a
sensor window for a rain sensor.
[0027] As described above, when looked through, the cutout in the
inner pane is arranged completely within the cutout in the second
thermoplastic intermediate layer; and, when looked through, the
cutout in the opaque layer or the region of a substrate layer
opaquely colored in some regions excluded from the opaque coloring
is arranged completely within the cutout of the inner pane.
[0028] Thus, in one embodiment, the cutout in the inner pane, the
cutout in the second thermoplastic intermediate layer, and the
cutout in the opaque layer or the region of the substrate layer
opaquely colored in some regions excluded from the opaque coloring
have the same outer dimensions and lie congruently one atop
another, when looked through.
[0029] In a preferred embodiment, the cutout in the second
thermoplastic intermediate layer prior to lamination of the
composite pane is larger in dimensions than the cutout in the inner
pane, wherein, when looked through, the cutout in the inner pane is
preferably arranged substantially centrally in the cutout in the
second thermoplastic intermediate layer. For example, the distance
between the inner edge of the second thermoplastic layer and the
inner edge of the inner pane prior to lamination is 5 mm to 10 mm.
This prevents the second thermoplastic intermediate layer from
flowing into the cutout in the inner pane during lamination.
Alternatively, flowing in of the second thermoplastic intermediate
layer during lamination can also be prevented by a barrier at the
inner edge of the second thermoplastic intermediate layer. Such a
barrier can, for example, be formed by Teflon strips and can,
optionally, be removed from the composite pane after
lamination.
[0030] In another preferred embodiment, the cutout in the opaque
layer or the region of the substrate layer opaquely colored in some
regions excluded from the opaque coloring is smaller in dimensions
than the cutout in the inner pane, wherein, when looked through,
the cutout in the opaque layer or in the region excluded from the
opaque coloring is preferably arranged substantially centrally in
the cutout in the inner pane. For example, the distance from the
inner edge of the opaque layer or from the inner edge of the region
that is opaquely colored to the inner edge of the inner pane is 5
mm to 50 mm, preferably, 7 mm to 10 mm. Thus, when looked through
from the outside, the inner edge of the inner pane is concealed by
the opaque layer or the opaquely colored region of a substrate
layer opaquely colored in some regions.
[0031] The composite pane according to the invention is in
particular intended and suitable for an optical sensor to be
secured on the pane that constitutes the inner pane in the
installed position. For this purpose, the interior-side surface of
the inner pane can be equipped with suitable mounts, for example,
with a bracket or a housing. The optical sensor secured to the
inner pane is preferably aimed toward the cutout in the inner
pane.
[0032] The optical sensors secured to the pane are preferably
cameras, such as video cameras or night vision cameras, rain
sensors, light sensors, distance meters, or LIDAR (light detection
and ranging) systems. If there is more than one optical sensor
secured to the pane, the type of the individual optical sensors can
even be different.
[0033] The substrate layer present in the inlay element can also be
implemented as an electrically conductive substrate layer. In this
case, the substrate layer contains or consists of an electrically
conductive polymer. Examples of conductive and thus heatable
polymers include poly-3,4-ethylenedioxythiophene (PEDOT) with
polystyrene sulfonate (PSS) as counterion, doped polyacetylene
(PAC), and polyaniline (PAni).
[0034] In a preferred embodiment of the composite pane accordin e
invention, the inlay element has at least one electrically
conductive element.
[0035] Thus, in one embodiment, the inlay element comprises a
substrate layer, an opaque layer, and at least one electrically
conductive element, wherein the opaque layer has a cutout which is,
when looked through, arranged completelywithin the cutout in the
inner pane. The at least one electrically conductive element can be
arranged directly adjacent the substrate layer, directly adjacent
the opaque layer, or between the substrate layer and the opaque
layer.
[0036] In another embodiment, the inlay element comprises a
substrate layer which is opaquely colored in some regions and at
least one electrically conductive element, wherein the substrate
layer has a region which is excluded from the opaque coloring and,
when looked through, is arranged completely within the cutout in
the inner pane. The at least one electrically conductive element
is, in this case, arranged directly adjacent the substrate
layer.
[0037] The at least one electrically conductive element can be
implemented, independently of one another, for example, as an
electrically heatable element, a moisture sensor, a pressure
sensor, an antenna, or a printed circuit board, i.e., a carrier for
electronic lines and components.
[0038] Examples of antennas include antennas for radio-frequency
identification (RFID), radio detection and ranging (RADAR), 5G,
long term evolution (LTE), global system for mobile communication
(GSM), global positioning system (GPS), radio (FM, DAB),
industrial, scientific, and medical band (ISM bands), and wireless
local area network (WLAN).
[0039] In one embodiment of the composite pane according to the
invention, the inlay element has at least two electrically
conductive elements that are structured differently.
[0040] The substrate layer and, if present, the opaque layer of the
inlay element have substantially the same outer dimensions. They
thus extend substantially over the entire length and width of the
inlay element.
[0041] "Substantially the same outer dimensions" means that the
outer dimensions of two materials deviate from one another by at
most 5%, preferably by 3%, particularly preferably by at most
2%.
[0042] The optionally present at least one electrically conductive
element extends over the entire surface or only in sections in the
inlay element.
[0043] If the inlay element has, for example, only one electrically
conductive element that is implemented in the form of an
electrically heatable layer or coating, this electrically heatable
layer or coating extends either over the entire surface or in
sections in the inlay element, i.e., the electrically heatable
layer or coating is arranged over the entire surface or
substantially over the entire surface or in sections on the
substrate layer or on the substrate layer and the opaque layer.
[0044] The at least one electrically conductive element can be an
electrically heatable coating, a carbon-containing layer, or a
metallic layer. Alternatively, the at least one electrically
conductive element can contain or be made of a conductive polymer.
It is known to the person skilled in the art which materials are
suitable as electrically conductive elements. For example, the at
least one electrically conductive element can be an indium tin
oxide (ITO) layer or coating, a layer or coating containing silver
or a silver-containing alloy, a layer or coating containing gold,
aluminum, or tungsten, a graphite-containing layer or coating, or
graphene. Examples of conductive and thus heatable polymers include
poly-3,4-ethylenedioxythiophene (PEDOT) with polystyrene sulfonate
(PSS) as counterion, doped polyacetylene (PAC), and polyaniline
(PAni).
[0045] The electrically conductive element is preferably between 5
.mu.m and 50 .mu.m thick, particularly preferably between 5 .mu.m
and 20 .mu.m, most particularly preferably between 8 .mu.m and 15
.mu.m. If the electrically conductive element is implemented, for
example, as an electrically heatable layer, it is, for example, 10
.mu.m thick. The electrically conductive element does not
necessarily have to have a constant thickness over its entire area.
The functional properties of the electrically conductive element
can be influenced by varying the thickness and the structuring of
the electrically conductive element.
[0046] In embodiments in which the conductive element is applied as
a coating on the substrate layer, the conductive element is
preferably between 10 nm and 5000 nm thick, preferably between 10
nm and 100 nm.
[0047] In a preferred embodiment, the substrate layer contains or
consists of polyethylene terephthalate (PET), polymethyl
methacrylate (PMMA), polypropylene (PP), or polyethylene (PE).
Particularly preferably, the substrate layer contains or is made of
PET.
[0048] The substrate layer is preferably between 50 .mu.m and 150
.mu.m thick, particularly preferably between 50 .mu.m and 100
.mu.m, most particularly preferably between 60 .mu.m and 80 .mu.m.
The substrate layer is, for example, 50 .mu.m thick.
[0049] As explained above, the substrate layer can be opaquely
colored in some regions.
[0050] In a preferred embodiment, the opaque layer of the
functional inlay element contains polyethylene terephthalate (PET)
or polyethylene (PE) or ethylene vinyl acetate copolymer (EVA), in
particular PET. In a particularly preferred embodiment, the opaque
layer of the functional inlay element is made of polyethylene
terephthalate (PET) or polyethylene (PE), in particular of PET.
[0051] The opaque layer is preferably between 50 .mu.m
(micrometers) and 200 .mu.m thick; particularly preferably, it has
the same thickness as the transparent substrate layer.
[0052] In embodiments in which the opaque layer is implemented as
an opaque coating on the substrate layer, the opaque coating is
preferably 5 .mu.m to 15 .mu.m thick.
[0053] It goes without saying that the opaque layer can also be
implemented as an opaque coating of the transparent substrate
layer. Suitable opaque coatings and printing methods for applying
the opaque coating to the substrate layer are known to the person
skilled in the art.
[0054] In preferred embodiments, the opaque layer or the opaquely
colored region of the transparent substrate layer is, at least in
sections, transparent to infrared radiation having a wavelength in
the range between 800 nm and 1560 nm. In these embodiments, the
opaque layer or the opaquely colored region of the transparent
substrate layer is thus transparent, at least in sections, to
radiation of infrared sensors or light detection and ranging
(LiDaR) sensors.
[0055] The first thermoplastic intermediate layer and the second
thermoplastic intermediate layer preferably contain, independently
of one another, ethylene vinyl acetate (EVA), polyvinyl butyral
(PVB), or polyurethane (PU) or mixtures or copolymers or
derivatives thereof, particularly preferably PVB, The thickness of
the first thermoplastic intermediate layer and the second
thermoplastic intermediate layer is, independently of one another,
preferably from 0.2 mm to 2 mm, particularly preferably from 0.3 mm
to 1 mm, for example, 0.38 mm or 0.76 mm. In one embodiment, the
thickness of the first thermoplastic intermediate layer is between
20 .mu.m and 120 .mu.m, preferably between 30 .mu.m and 90 .mu.m,
particularly preferably between 50 .mu.m and 75 .mu.m, and most
particularly preferably 50 .mu.m.
[0056] The first thermoplastic intermediate layer and/or the second
thermoplastic intermediate layer can also be sprayed onto the
substrate layer or the substrate layer opaquely colored in some
regions.
[0057] It goes without saying that in embodiments, the composite
pane according to the invention can have further thermoplastic
and/or functional layers, in addition to the first thermoplastic
layer, the second thermoplastic layer, and the inlay element.
[0058] In a preferred embodiment of a composite pane according to
the invention, the opaque layer or the opaquely colored region of
the substrate layer is black. The opaque layer or the opaquely
colored region of the substrate layer can, however, also be any
other color. The opaque layer can be a layer colored all the way
through or an imprinted layer or can be realized by an opaque
coating.
[0059] A composite pane according to the invention can additionally
include a masking print, in particular made of a dark, preferably
black, enamel. Preferably, the opaque layer or the opaquely colored
region of the substrate layer and the masking print have
substantially the same optical density. The masking print is in
particular a peripheral, i.e., frame-like, masking print. The
peripheral masking print serves primarily as UV protection for the
assembly adhesive of the composite pane. The masking print can be
opaque and cover the entire surface. The masking print can be
implemented semitransparent, at least in sections, for example, as
a point grid, a strip grid, or a checkered grid. Alternatively, the
masking print can also have a gradient, for example, from an opaque
covering to a semitransparent covering.
[0060] "Substantially the same optical density" means that the
optical densities of two materials differ from one another by at
most 5%, preferably by 3%, particularly preferably by at most
2%.
[0061] In a preferred embodiment of a composite pane according to
the invention, it includes a masking print that is the same color
as the opaque layer or the opaquely colored region of the substrate
layer.
[0062] The masking print is usually applied to the interior-side
surface of the outer pane or to the interior-side surface of the
inner pane.
[0063] Preferably, the iniay element is arranged between the outer
pane and the inner pane such that, in the embodiments in which the
inlay element comprises a substrate layer and an opaque layer, the
opaque layer of the inlay element is arranged as directly adjacent
the first thermoplastic intermediate layer as possible. In such an
arrangement, in top view from the outside, the supply lines and
connections of the optionally present at least one electrically
conductive element are concealed by the opaque layer.
Alternatively, the supply lines and connections can also be largely
or completely embedded in the opaque layer.
[0064] The outer pane, the inner pane, the first thermoplastic
intermediate layer, and the second thermoplastic intermediate layer
can, independently of one another, be dear and colorless, but also
tinted, frosted, or colored. The total transmittance through the
composite pane is, in a preferred embodiment, greater than 70%, in
particular when the composite pane is a windshield, The term "total
transmittance" is based on the process for testing the light
permeability of motor vehicle windows specified by ECE-R 43, Annex
3, .sctn. 9.1. The outer pane and the inner pane can be made of
non-tempered, partially tempered, or tempered glass. The thickness
of the outer pane and the inner pane is typically from 0.3 mm to 5
mm, preferably from 1 mm to 3 mm, for example, 2.1 mm.
[0065] The composite pane is preferably curved in one or a
plurality of spatial directions, as is customary for motor vehicle
windows, with typical radii of curvature in the range from approx.
10 cm to approx. 40 m. The composite glass can, however, also be
flat, for example, when it is intended as a pane for buses, trains,
or tractors.
[0066] In a preferred embodiment, the composite pane is a vehicle
composite pane, in particular a windshield.
[0067] In one embodiment, the composite pane is a windshield which
is mirror-symmetrical along a center line, and the inlay element is
arranged on the center line near the upper edge of the
windshield.
[0068] "Near the upper edge" means, in particular, that the
distance between the inlay element and the upper edge is at most 30
mm, preferably at most 20 mm, particularly preferably at most 15
mm, most particularly preferably at most 10 mm.
[0069] The optionally present at least one electrically conductive
element can be connected to a voltage source. Each electrically
conductive element can be connected to its own voltage source, or
multiple electrically conductive elements can be connected to the
same voltage source.
[0070] Usually used in the vehicle sector as a supply line for the
contacting of electrically conductive elements in the interior of
composite panes are foil conductors. Examples of foil conductors
are described in DE 42 35 063 A1, DE 20 2004 019 286 U1, and DE 93
13 394 U1.
[0071] A further aspect of the invention is an arrangement
comprising a composite pane according to the invention and an
optical sensor applied thereon that is secured to the interior-side
surface of the inner pane facing away from the second thermoplastic
intermediate layer.
[0072] In one embodiment of this arrangement, the inlay element has
a substrate layer and an opaque layer, and the opaque layer has a
cutout which is, when looked through, arranged completely within
the cutout in the inner pane. In this embodiment, the optical
sensor is directed toward the region of the cutout in the opaque
layer, i.e., the sensor window. The detection beam path of the
sensor thus runs through the cutout in the opaque layer. The
optical sensor is preferably an optical camera, in other words, a
camera with sensitivity in the visible spectral range, for example,
a lane camera or a camera for an augmented reality head-up
display.
[0073] In another embodiment of this arrangement, the inlay element
has a substrate layer which is opaquely colored in some regions and
has a region which is excluded from the opaque coloring and is,
when looked through, arranged completely within the cutout of the
inner pane. In this embodiment, the optical sensor is directed
toward the region of the substrate layer excluded from the opaque
coloring, i.e., the sensor window. The detection beam path of the
sensor thus runs through the region excluded from the opaque
coloring. The optical sensor is preferably an optical camera, in
other words, a camera with sensitivity in the visible spectral
range, for example, a lane camera or a camera for an augmented
reality head-up display.
[0074] In another embodiment of this arrangement, the inlay element
has a substrate layer and an opaque layer, and the opaque layer is,
at least in sections, transparent to infrared radiation with a
wavelength in the range between 800 nm and 1560 nm, and the optical
sensor is an infrared sensor or a light detection and ranging
(LiDaR) sensor that is directed toward the section that is
transparent to infrared radiation with a wavelength in the range
between 800 nm and 1560 nm. The detection beam path of the sensor
thus runs through the section in the opaque layer that is
transparent to infrared radiation with a wavelength in the range
between 800 nm and 1560 nm.
[0075] In another embodiment of this arrangement, the inlay element
has a substrate layer which is opaquely colored in some regions,
and the opaquely colored region of the substrate layer is, at least
in sections, transparent to infrared radiation with a wavelength in
the range between 800 nm and 1560 nm, and the optical sensor is an
infrared sensor or a light detection and ranging (LiDaR) sensor
that is directed toward the section that is transparent to infrared
radiation with a wavelength in the range between 800 nm and 1560
nm. The detection beam path of the sensor thus runs through the
section in the substrate layer that is transparent to infrared
radiation with a wavelength in the range between 800 nm and 1560
nm.
[0076] The composite pane according to the invention meets the
legal requirements with regard to fragment configurations in crash
tests, for example, in accordance with ECE Regulation R43.
[0077] With a composite pane according to the invention, the
refractive forces in the region of the sensor window are reduced by
more than 50% compared to a composite pane in which the inner pane
has no cutout in the region of the sensor window. Typical remaining
refractive forces are in the range from 10 to 70 millidiopters
(mdpt).
[0078] The invention also relates to a method for producing a
composite pane, at least comprising the following steps: [0079] (a)
Providing an outer pane, an inner pane which has a cutout, a first
thermoplastic intermediate layer, a second thermoplastic
intermediate layer which has a cutout, and an inlay element; [0080]
(b) Arranging the first thermoplastic intermediate layer directly
adjacent the outer pane, the second thermoplastic intermediate
layer directly adjacent the inner pane, and the inlay element
between the first thermoplastic intermediate layer and the second
intermediate layer such that the cutout of the second thermoplastic
intermediate layer is, when looked through, arranged completely
within the region in which the inlay element is arranged, and the
cutout of the inner pane is, when looked through, arranged
completely within the cutout of the second thermoplastic
intermediate layer; and [0081] (c) Joining the outer pane to the
inner pane by lamination via the first thermoplastic intermediate
layer and the second thermoplastic intermediate layer.
[0082] The arranging of the inlay element between the first
thermoplastic intermediate layer and the second thermoplastic
intermediate layer can be done manually or mechanically, for
example, by means of a robot.
[0083] If the inlay element has a substrate layer and an opaque
layer that has a cutout, or if the inlay element has a substrate
layer that is opaquely colored in some regions and has a region
that is excluded from the opaque coloring, in step (b) of the
method, the inlay element is arranged between the first
thermoplastic intermediate layer and the second thermoplastic
intermediate layer such that, when looked through, the cut out in
the opaque layer or the part of the substrate layer opaquely
colored in some regions excluded from the region of the opaque
coloring is arranged completely within the cutout of the inner
pane.
[0084] In embodiments of the method in which the inlay element has
at least one electrically conductive element, the providing of the
inlay element, i.e., the arranging of the substrate layer, the at
least one electrically conductive element and, if present, the
opaque layer can be done manually or mechanically, for example, by
means of a robot. Appropriate inlay elements can be prefabricated
and tested and then arranged in the connector line between the
first and the second pane during production of the composite
pane.
[0085] The at least one electrically conductive element can be
processed, for example, using laser techniques, cutting methods,
printing methods, etching methods, adhesive methods, chemical vapor
deposition (CVD), physical vapor deposition (PVD), or atomic layer
deposition (ALD).
[0086] If the composite pane is to have a curve, as is customary in
particular for passenger cars, the panes are subjected to a bending
process before lamination, for example, by gravity bending, suction
bending, and/or press bending. Typical bending temperatures are
from 500.degree. C. to 700.degree. C.
[0087] Preferably, before lamination and before the optional
bending, an opaque masking print is applied, in particular to the
edge region of the outer pane and/or the inner pane. For this, a
black or dark enamel is typically applied by screen printing and
baked before lamination, in particular before bending or during
bending.
[0088] The invention also relates to the use of a composite pane
according to the invention as a vehicle pane, preferably as a
windshield of a motor vehicle.
[0089] The various embodiments of the invention can be implemented
individually or in any combinations. In particular, the features
mentioned above and explained in the following can be used not only
in the combinations mentioned but also in other combinations or in
isolation, without departing from the scope of the present
invention.
[0090] In the following, the invention is explained in detail with
reference to drawings and exemplary embodiments. The drawings are
schematic representations and not to scale. The drawings in no way
restrict the invention.
[0091] They depict:
[0092] FIG. 1 a plan view of an embodiment of the composite pane
according to the invention,
[0093] FIG. 2 a detail of a cross-section through an embodiment of
the composite pane according to the invention of FIG. 1 along the
center line M,
[0094] FIG. 3 a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M,
[0095] FIG. 4 a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M,
[0096] FIG. 5 a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M,
[0097] FIG. 6 a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M,
[0098] FIG. 7 a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M,
[0099] FIG. 8 a plan view of an embodiment of an inlay element,
[0100] FIG. 9 a plan view of another embodiment of the composite
pane according to the invention,
[0101] FIG. 10 a flowchart of an embodiment of the method according
to the invention.
[0102] FIG. 1 depicts an embodiment of the composite pane 1
according to the invention, and FIG. 2 depicts the detail of a
cross-section through an embodiment of the composite pane 1
according to the invention of FIG. 1 along the center line M. The
composite pane 1 depicted in FIG. 1 is mirror-symmetrical along the
center line M, and the functional inlay element 5 is arranged on
the center line near the upper edge O.
[0103] In the embodiment depicted in FIGS. 1 and 2, the composite
pane 1 comprises an outer pane 2 and an inner pane 3 that are
joined to one another, surface to surface, via a first
thermoplastic intermediate layer 4a arranged directly adjacent the
outer pane 2 and a second thermoplastic intermediate layer 4b
arranged directly adjacent the inner pane 3. The outer pane 2 and
the inner pane 3 are made of soda lime glass and have, for example,
a thickness of 2.1 mm. An inlay element 5 is arranged between the
first thermoplastic intermediate layer 4a and the second
thermoplastic intermediate layer 4b . The first thermoplastic
intermediate layer 4a and the second thermoplastic intermediate
layer 4b are made, in the embodiment depicted in FIGS. 1 and 2, of
polyvinyl butyral (PVB) and are in each case 0.76 mm thick. The
inlay element 5 has, in the embodiment depicted in FIGS. 1 and 2, a
trapezoidal shape, wherein the corners pointing toward the lower
edge are rounded. However, any other outer shape of the inlay
element 5 suitable for masking sensors is possible. The second
thermoplastic intermediate layer 4b has a cutout 7, wherein the
cutout 7 is, when looked through, arranged completely within the
region in which the inlay element 5 is arranged. The inner pane 3
has a cutout 6. This is, when looked through, arranged completely
within the cutout 7 of the second thermoplastic intermediate layer
4b . In the embodiment depicted in FIG. 2, the inner edge 16 of the
inner pane 3 and the inner edge 17 of the second thermoplastic
layer 4b are, when looked through, arranged congruently one atop
another. However, it is also possible for the cutout 7 in the
second thermoplastic intermediate layer 4b to be larger than the
cutout 6 in the inner pane, and the distance of the inner edge 17
of the second thermoplastic layer 4b from the inner edge 16 of the
inner pane 3 is, for example, 5 mm.
[0104] FIG. 3 depicts a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the centerline M, which differs from the embodiment
depicted in FIG. 2 only in that it additionally includes an optical
sensor 14 that is attached to the inner pane 3 via a mount 15. The
optical sensor is directed toward the cutout 6 (not provided with a
reference character in FIG. 3) of the inner pane. The optical
sensor 14 is, for example, a lane camera or a LIDAR sensor. The
detection direction of the optical sensor 14 is directed forward
roughly horizontally outside the composite pane 1. Radiation that
passes horizontally through the vehicle composite pane 1 in a
so-called sensor window is detected by the optical sensor 14.
[0105] FIG. 4 depicts a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M, which differs from the embodiment
depicted in FIG. 2 only in that it shows that the inlay element 5
has a substrate layer 8 and an opaque layer 9. The opaque layer 9
has a cutout 10 which is, when looked through, arranged completely
within the cutout 6 of the inner pane 3. During lamination of the
composite pane, the first thermoplastic intermediate layer 4a flows
into the cutout 10 of the opaque layer 9. This is also the case in
the embodiment depicted in FIG. 4. The distance of the inner edge
18 of the opaque layer 9 from inner edge 16 of the inner pane 3 is,
for example, 10 mm. In the embodiment depicted in FIG. 4, the
substrate layer 8 is, for example, a transparent PET film with a
thickness of 60 .mu.m; and the opaque layer 9, a PET film with a
thickness of 50 .mu.m.
[0106] FIG. 5 depicts a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M which differs from the embodiment
depicted in FIG. 2 only in that it shows that the inlay element 5
has a substrate layer 8 which is opaquely colored in some regions
(the opaquely colored region is provided with the reference
character 8a). The region 11 of the substrate layer that is
excluded from the opaque coloring and is thus transparent is, when
looked through, arranged completely within the cutout 6 of the
inner pane 3. The distance of the inner edge 19 of the region 11
from the inner edge 16 of the inner pane 3 is, for example, 10 mm.
In the embodiment depicted in FIG. 5, the substrate layer 8 is, for
example, a PET film with a thickness of 80 .mu.m.
[0107] FIG. 6 depicts a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the centerline M which differs from the embodiment depicted
in FIG. 4 only in that the inlay element 5 additionally has an
electrically conductive element 12 that is implemented as an
electrically heatable layer 12a , The electrically conductive
element 12 is arranged between the opaque layer 9 and the substrate
layer 8. The electrically conductive element 12 is, in the
embodiment depicted in FIG. 6, larger in terms of its outer
dimensions than the cutout 6 in the inner pane 3. The electrically
conductive layer 12 is arranged such that, when looked through, the
cutout 6 in the inner pane 3 is arranged completely within the
region in which the electrically conductive element 12 is arranged.
The electrically conductive element 12 is, in the embodiment
depicted in FIG. 6, an electrically conductive polymer, such as
polyaniline with a thickness of 100 nm.
[0108] FIG. 7 depicts a detail of a cross-section through another
embodiment of the composite pane according to the invention of FIG.
1 along the center line M which differs from the embodiment
depicted in FIG. 5 only in that the inlay element 5 additionally
has an electrically conductive element 12 that is implemented as an
electrically heatable coating 12a . The electrically heatable
coating 12a is applied on the substrate layer 8 in the direction of
the inner pane 3. The electrically heatable coating 12a is, in the
embodiment depicted in FIG. 7, larger in terms of its outer
dimensions than the cutout 6 in the inner pane 3. The electrically
heatable coating 12a is arranged such that, when looked through,
the cutout 6 in the inner pane 3 is arranged completely within the
region in which the electrically conductive element 12 in the form
of an electrically heatable coating 12a is arranged. The
electrically conductive element 12 is, in the embodiment depicted
in FIG. 7, an ITO coating with a thickness of 50 nm applied on the
substrate layer 8 opaquely colored in some regions.
[0109] FIG. 8 depicts the plan view of an embodiment of an inlay
element 5. In the embodiment of the inlay element 5 depicted in
FIG. 8, it has a substrate layer 8 opaquely colored in some
regions. The region 11, which is excluded from the opaque coloring
and is thus transparent, is trapezoidal and, for better
illustration, is bordered in FIG. 8 with a dashed line. In the
embodiment of an inlay element 5 depicted in plan view in FIG. 8,
the inlay element 5 has four electrically conductive elements 12.
It is, however, also possible for the inlay element to have more or
fewer electrically conductive elements 12. For better illustration,
the electrically conductive elements 12 are shown patterned in FIG.
8. One of these electrically conductive elements 12 is a heatable
element 12a implemented with a substantially triangular region with
two lines extending therefrom. Another of these electrically
conductive elements 12 is implemented as an antenna 12b , for
example, a GPS antenna, with a substantially square region with one
line extending therefrom. Two more of these electrically conductive
elements 12 together are a moisture sensor 12c which is implemented
as two substantially rectangular regions, each with one line
extending therefrom. As is discernible from FIG. 8, the
substantially triangular region of the heatable element 12a is
slightly larger than the region 11 of the substrate layer 8
excluded from the opaque coloring and the region 11 excluded from
the opaque coloring lies, when looked through, completely within
the triangular region of the heatable element 12a.
[0110] FIG. 9 depicts another embodiment of a composite pane 1
according to the invention. The composite pane 1 depicted in FIG. 9
differs from that depicted in FIG. 1 only in that it additionally
includes a peripheral masking print 13 made of enamel. The opaque
layer 9 or the opaquely colored region of the transparent substrate
layer 8 of the inlay element 5 and the peripheral masking print 13
have substantially the same optical density and are, in the
embodiment depicted in FIG. 13, shown patterned in each case. In
the embodiment depicted in FIG. 9, the peripheral masking print 13
is applied only adjacent the outer edges of the composite pane 1.
However, it is also possible for yet another masking print 13 to be
additionally applied around the inlay element 5 on the outside.
[0111] FIG. 10 shows the flow chart of a method according to the
invention for producing a composite pane 1 according to the
invention. In a first step I, an outer pane 2, an inner pane 3
which has a cutout 6, a first thermoplastic intermediate layer 4a ,
a second thermoplastic intermediate layer 4b which has a cutout 7,
and an inlay element 5 are provided. In a second step II, the first
thermoplastic intermediate layer 4a is arranged directly adjacent
the outer pane 2, the second thermoplastic intermediate layer 4b is
arranged directly adjacent the inner pane 3, and the inlay element
5 is arranged between the first thermoplastic intermediate layer 4a
and the second intermediate layer 4b such that the cutout 7 of the
second thermoplastic intermediate layer 4b is, when looked through,
arranged completely within the region in which the inlay element 5
is arranged; and the cutout 6 of the inner pane 3 is, when looked
through, arranged completely within the cutout 7 of the second
thermoplastic intermediate layer 4b . In a third step III, the
outer pane is joined to the inner pane 3 by lamination via the
first thermoplastic intermediate layer 4a and the second
thermoplastic intermediate layer 4b.
LIST OF REFERENCE CHARACTERS
[0112] 1 composite pane
[0113] 2 outer pane
[0114] 3 inner pane
[0115] 4a first thermoplastic intermediate layer
[0116] 4b second thermoplastic intermediate layer
[0117] 5 inlay element
[0118] 6 cutout (in the inner pane)
[0119] 7 cutout (in the second thermoplastic intermediate
layer)
[0120] 8 substrate layer
[0121] 8a opaquely colored region of the substrate layer
[0122] opaque layer
[0123] 10 cutout (in the opaque layer)
[0124] 11 region (which is excluded from the opaque coloring)
[0125] 12 electrically conductive element
[0126] 12a electrically heatable element, electrically heatable
layer, electrically heatable coating
[0127] 12b antenna
[0128] 12c moisture sensor
[0129] 13 masking print
[0130] 14 sensor
[0131] 15 mount
[0132] 16 inner edge of the inner pane
[0133] 17 inner edge of the second thermoplastic intermediate
layer
[0134] 18 inner edge of the opaque layer
[0135] 19 inner edge of the region 11
[0136] O upper edge/roof edge of the composite pane
[0137] U lower edge/engine edge of the composite pane
[0138] M center line
* * * * *